Alignment system for mating connectors

ABSTRACT

An alignment system is provided between a pair of connectors mateable in a given mating direction. A first connector includes a housing having an alignment projection on one side thereof. A second connector includes a housing having an alignment flange projecting forwardly thereof generally in said mating direction. The alignment flange is flared outwardly for engaging the housing of the first connector during mating and allowing a degree of misalignment between the connectors in an “X” direction generally perpendicular to the mating direction. The alignment flange includes a slot for receiving the alignment projection of the first connector. The slot has a flared mouth allowing a degree of misaligned between the connectors in a “Y” direction generally perpendicular to the mating direction and generally perpendicular to the “X” direction.

FIELD OF THE INVENTION

This invention generally relates to the art of connector assemblies and,particularly, to an alignment system between a pair of mateableconnectors.

BACKGROUND OF THE INVENTION

Fiber optic connectors of a wide variety of designs have been employedto terminate optical fiber cables and to facilitate connection of thecables to other cables or other optical fiber transmission devices. Atypical fiber optic connector includes a ferrule which mounts andcenters an optical fiber or fibers within the connector. The ferrule maybe fabricated of such material as ceramic. A ferrule holder or otherhousing component of the connector embraces the ferrule and may befabricated of such material as molded plastic. A spring may be disposedwithin the housing or ferrule holder such that the ferrule is yieldablybiased forwardly for engaging another fiber-mounting ferrule of a matingconnecting device.

A pair of fiber optic connectors or a connector and another opticalfiber transmission device often are mated in an adapter which centersthe fibers to provide low insertion losses. The adapter couples theconnectors together so that their encapsulated fibers connectend-to-end. The adapter may be an in-line component, or the adapter canbe designed for mounting in an opening in a panel, backplane, circuitboard or the like.

Various problems continue to be encountered in designing fiber opticconnector assemblies or other connector assemblies, includingapplications involving backplanes, motherboards, daughterboards and thelike. Such problems include properly and precisely placing a connectorassembly on a substrate, such as a printed circuit board, accommodatingmisalignment of the connectors during mating, allowing relative floatingmovement between various components of the system and similarpositional-type problems. Other problems simply involve efforts tosimplify the design of connector assemblies. The present invention isdirected to solving these problems and to providing various improvementsin such connector assemblies.

SUMMARY OF THE INVENTION

An object, therefore, of the invention is to provide a new and improvedalignment system between a pair of connectors mateable in a given matingdirection.

In the exemplary embodiment of the invent ion, a first connectorincludes a housing having an alignment projection on one side thereofextending generally transversely of the mating direction. A secondconnector includes a housing having an alignment flante projectingforwardly thereof generally in the mating direction. The alignmentflange is flared outwardly generally transversely of the matingdirection for engaging the housing, of the first connector during matingand allowing a degree of misalignment between the connectors in an “X”direction generally perpendicular to the mating direction. The alignmentflange further includes a slot for receiving the alignment projection ofthe first connector. The slot has a flared mouth allowing a degree ofmisalignment between the connectors in a “Y” direction generallyperpendicular to the mating direction and generally perpendicular to the“X” direction. Therefore, the single flange of the second connector, inoperative association with the alignment projection on the firstconnector, provides for a decree of misalignment in two differentmutually transverse directions.

As disclosed herein, the alignment projection on the housing of thefirst connector is formed by a projecting rib which is elongated in themating direction. The first connector comprises an open-ended adapter,with one open end for mating with the second connector. The secondconnector comprises a fiber optic connector.

In the preferred embodiment, a pair of the alignment flanges areprovided on the housing of the second connector spaced transversely ofthe mating direction and between which the second connector is matedwith the first connector. The transversely spaced flanges are formed byforwardly projecting alms having distal ends with inside surfaces whichare diverging flared away from the housing of the second connector. Eacharm includes one of the slots in the inside thereof. Each slot has aflared mouth, and the housing of the first connector has one of thealignment projections on opposite sides thereof for receipt in theslots.

Other objects, features and advantages of the invention will be apparentfrom the following detailed description taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention which are believed to be novel are setforth with particularity in the appended claims. The invention, togetherwith its objects and the advantages thereof, may be best understood byreference to the following description taken in conjunction with theaccompanying drawings, in which like reference numerals identify likeelements in the figures and in which:

FIG. 1 is a perpective view of a mating connector assembly embodying theconcepts of the invention with the assembly in unmated condition;

FIG. 2 is a side elevational view of the mating connector assembly asshown in FIG. 1;

FIG. 3 is a perspective view of the mating connector assembly of FIG. 1,in mated condition;

FIG. 4 is an exploded perspective view of the backplane connectorassembly as seen to the left in FIGS. 1 and 2;

FIG. 5 is a perspective view of one of the shutter assemblies for theadapter in the backplane connector assembly of FIG. 4;

FIG. 6 is a perspective view of the other shutter assembly for theadapter;

FIG. 7 is an enlarged perspective view, broken away to show the floatingmount between the adapter and the backplane in the backplane connectorassembly of FIG. 4;

FIG. 8 is a perspective view of one of the fiber optic connector modulesof the backplane connector assembly of FIG. 4;

FIG. 9 is a perspective view of the housing of the connector module ofFIG. 8;

FIG. 10 is a perspective view showing the assembly procedure of themodule of FIG. 8;

FIG. 11 is an exploded perspective view of the daughterboard connectorassembly as seen to the right of FIGS. 1 and 2;

FIG. 12 is an exploded bottom perspective view of the two-part housingof the daughterboard connector assembly;

FIG. 13 is a perspective view of the front housing part of thedaughterboard connector assembly;

FIG. 14 is a perspective view of one of the fiber optic connectormodules of the daughterboard connector assembly of FIG. 11;

FIG. 15 is an exploded perspective view of the module of FIG. 14;

FIG. 16 is a perspective view of the pin keeper of the module of FIG.14;

FIG. 17 is a perspective view of the spring pusher member of the moduleof FIG. 14;

FIG. 18 is a perspective view showing the assembly of the coil spring tothe pin keeper of FIG. 16;

FIG. 19 is a perspective view showing the assembly of the spring to thepusher member of FIG. 17; and

FIGS. 20-22 are sequential top plan views, partially broken away,showing the mating of the mating connector assembly of FIGS. 1-3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in greater detail, and first to FIGS. 1-3, theinvention is embodied in a mating connector assembly, generallydesignated 24, which includes a backplane connector assembly, generallydesignated 26, mateable with a daughterboard connector assembly,generally designated 28. The backplane connector assembly is mounted inan aperture 30 in a substrate, panel or backplane which, in thepreferred embodiment, is a pianted circuit board. Specifically,backplane 32 can be considered the “motherboard” herein. Thedaughterboard connector assembly is mounted on a top surface of a secondprinted circuit board 34 which is considered the “daughterboard” herein.

Backplane connector assembly 26 includes an adapter, generallydesignated 36, which is mounted in aperture 30 in motherboard 32. Fourfiber optic connector modules, generally designated 38, are insertedinto adapter 36, through aperture 30, from the front of backplane 32.Each fiber optic connector module is terminated to a multi-fiber cable40. Each cable is a flat or “ribbon” cable having a plurality of opticalfibers.

After daughterboard connector assembly 28 is mounted on daughterboard34, four fiber optic connector modules, generally designated 42, areinserted into the back of the connector housing, as describedhereinafter. Each module 42 is terminated to a flat, multi-fiber cable44 similar to fiber optic cables 40. Backplane connector assembly 26 anddaughterboard connector assembly 28 are mateable in the direction ofarrows “A” (FIGS. 1 and 2) to a mated condition shown in FIG. 3, whereinthe fibers of cables 40 and 44 are functionally connected.

Referring to FIG. 4, adapter 36 includes a housing 46 which may befabricated of molded plastic material. The housing defines a frontmating end 46 a and a rear terminating end 46 b. The front mating end isopen, as at 46 c, and through which the ferrules (described hereinafter)of fiber optic connector modules 38 can project. Terminating end 46 b isopen, as at 46 d, for receiving connector modules 38 in the direction ofarrows “B”. Housing 46 of adapter 36 has an outwardly projectingalignment rib 48 on each opposite side thereof and extending in themating direction of the connector assembly, for purposes describedhereinafter.

FIG. 5 shows a shutter assembly, generally designated 50, for closingopening 46 b of adapter 46, and FIG. 6 shows a shutter assembly,generally designated 52, for closing mating opening 46 c of the adapter.Shutter assembly 50 includes a pair of spring-loaded shutters 50 a whichclose opening 46 d on opposite sides of an interior partition 54 (FIG.4). The shutter members are pivotally mounted on a plate 50 b whichincludes a plurality of pegs 50 c which are press-fit into holes 56 inadapter housing 46. Similarly, shutter 52 a of shutter assembly 52 isspring-loaded and is mounted on a plate 52 b which has a plurality ofpegs 52 c which are press-fit into a plurality of holes 58 in adapterhousing 46. Shutters 50 a and 52 a provide dust covers for the interiorof adapter 36.

Referring to FIG. 7 in conjunction with FIG. 4, means are provided formounting adapter 36 to backplane 32 in order to provide relativefloating movement therebetween. Specifically, a pair of T-nuts,generally designated 60, are floatingly mounted to adapter 36 andreceive a pair of rivets 62 insertable in the direction of arrows “C”through a pair of mounting holes 64 in the backplane. The rivets haveenlarged head portions 62 a which will engage the surface of thebackplane. Mounting holes 64 are spaced on opposite sides of opening 30.

Still further, each T-nut 60 includes a shank portion 60 a and anenlarged head 60 b. A mounting flange, generally designed 66, is moldedintegrally with each opposite side of adapter housing 46. Each flange 66includes an interior cavity 66 a which receives head portion 60 b of oneof the T-nuts 60. A passage 66 b extends through flange 66 towardbackplane 32 in communication with cavity 66 a for receiving shankportion 60 a of the Tnut. The following parameters should be understood:(1) the dimensions of head portion 60 b are smaller than cavity 66 a sothat the head portion can float within the cavity, (b) the crossdimensions of shank portion 60 a are less than the dimensions of passage66 b so that the shank portion can float within the passage and (c) thelength of shank portion 60 a is greater than the thickness of a wallportion 67 of flange 66 below the head portion (i.e., the thicknessindicated by double-headed arrow “D” (FIG. 7). Therefore, when rivet 62tightens the T-nut onto surface 32 a of backplane 32, the adapter doesnot become tightened to the backplane and is allowed to float relativethereto. Lastly, passage 66 b has a restricted mouth, as at 66 e. sothat the T-nut can be snap-fit into flange 66 to mount the nut toadapter housing 46. It should be understood that rivet 62 equally couldbe a threaded fastener, such as a screw, for threadingly engaging theT-nut.

FIGS. 8-10 show one of the fiber optic connector modules 38 which areinserted into adapter 36 as described above. Specifically, each module38 includes a ferrule 68 terminated to one of the multi-fiber cables 40with ends 40 a (FIG. 8) of the fibers exposed at a mating face 68 a ofthe ferrule. The ferrule includes a pair of alignment holes 68 b openinginto mating face 68 a. The ferrule is captured by a manuallymanipulatable housing, generally designated 70, which includes a frontportion 70 a which actually captures the ferrule, and a rear portiondefined by a pair of laterally spaced aims 70 b that are graspablebetween an operator's fingers. FIG. 10 shows that ferrule 68 has aperipheral flange 68 c. The front portion 70 a of housing 70 includes apair of forward latch hooks 70 c on two opposite sides of the housingand a pair of flexible latch arms 70 d on the other two opposite sidesof the housing. As seen best in FIG. 9, each latch aim 70 d includes aninside chamfered latch hook 70 e. Latch hooks 70 c engage the front offlange 68 c of the ferrule, and latch hooks 70 e on latch arms 70 dengage the rear edges of flange 68 c to hold the ferrule encapsulatedwithin front portion 70 a of housing 70.

Still referring to FIGS. 8-10, manually graspable arms 70 includeserrations 71 on the outsides thereof to facilitate manual graspingthereof. A latch block 70 f projects outwardly from each arm forlatching engagement within adapter 36. Each arm 70 b also includes aninterior channel 70 g for guiding ferrule 68 into front portion 70 a ofthe housing.

FIG. 10 shows that ferrule 68 is insertable into housing 70 of connectormodule 38 in the direction of arrow “E”. The ferrule moves withinchannels 70 g of arms 70 b and through an open rear end 70 h of frontportion 70 a of the housing. The ferrule becomes latched in a positionprojecting out of an open front end 70 i (FIG. 9) of the housing and islocked in the position shown in FIG. 8, with the ferrule projectingforwardly of the manually manipulatable housing.

FIGS. 11-13 show daughterboard connector assembly 28 to include atwopart housing defined by a front housing part, generally designated72, and a rear housing part, generally designated 74. The rear housingpart is insertable into the front housing part in the direction of arrow“F” (FIG. 11). Rear housing part 74 has a flexible latch arm 74 a with alatch hook 74 b which latches behind a front latch shoulder 72 a (FIG.13) when the two housing parts are initially assembled. FIG. 13 alsoshows a second latch shoulder 72 b which is located rearwardly of latchshoulder 72 a, for purposes described hereinafter. Each housing part 72and 74 may be a one-piece structure unitarily molded of dielectricmaterial such as plastic or the like.

Generally, a system is provided for mounting front housing part 72 ofdaughterboard connector assembly 28 on daughterboard 34 withconsiderable precision. Specifically, the daughterboard has apre-placement hole 76 spaced between a pair of positioning holes 78 ofas seen in FIG. 11. A pair of rivets 80 are insertable throughpositioning holes 78. As best seen in FIG. 12, a pre-positioning peg 82projects downwardly from a bottom surface 72 d of front housing part 72for insertion into pre-placement hole 76 with substantially zeroinsertion forces. In other words, hole 76 is larger than peg 82. A pairof positioning pegs 84 project downwardly from surface 70 d forinsertion into positioning holes 78 in daughterboard 34 by a press-fitto precisely fix the housing on the substrate. Peg 82 is solid, but pegs84 are hollow for receiving rivets 80 therethrough to solidly lock thefront housing part to the daughterboard. Pre-placement peg 82 is longerthan positioning pegs 84 so that it is easy for an operator to locateand insert pre-placement peg 82 into pre-placement hole 76. The housingthen can be easily pivoted about peg 82 until positioning pegs 84 arealigned with positioning holes 78.

Still referring to FIG. 12, positioning pegs 84 are provided withcrushable ribs 84 a on the exterior thereof and which are crushed ordeformed when pegs 84 are pressfit into holes 78. Bottom surface 72 d offront housing part 72 is recessed, as at 86, around each positioning peg84. This recessed area is provided for receiving any plastic material,such as crushable fibs 84 a, which might be shaved off of positioningpegs 84 when they are press-fit into positioning holes 78. This ensuresthat bottom surface 72 d of front housing part 72 is mounted flush onthe flat top surface of daughterboard 34.

Generally, an alignment system is provided between daughterboardconnector assembly 28 and adapter 36 of backplane connector assembly 26.More particularly, as best seen in FIGS. 11 and 12, front housing part72 includes a pair of alignment flanges 88 at opposite sides of an openmating end 72 e of the front housing part. Each flange has an outwardlychamfered or flared distal end 88 a which is engageable by the frontedges 90 (FIG. 1) of adapter 36 upon mating of the two connectorassemblies. In essence, flared distal ends 88 a allow for a degree ofmisalignment between the connector assemblies in an “X” directiongenerally perpendicular to mating direction “A” (FIG. 1) of theconnectors, the “X” direction being generally parallel to daughterboard34. Alignment flanges 88 have grooves or slots 88 b on the insidesthereof for receiving alignment ribs 48 (FIG. 1) on opposite sides ofadapter housing 46. Slots 88 b have flared mouths 88 c which areengageable by the distal ends of alignment ribs 48 to allow for a degreeof misalignment between the two connector assemblies in a “Y” directiongenerally perpendicular to mating direction “A” as well as generallyperpendicular to the aforesaid “X” direction and daughterboard 44.Therefore, alignment flanges 88, with the outwardly flared distal ends88 a thereof in combination with flared mouths 88 c of slots 88 b, areunique in utilizing a singular structure to allow for misalignment intwo different “X” and “Y” directions.

Referring back to FIG. 2 in conjunction with FIGS. 11 and 12, a bottomflange 92 projects forwardly of front housing part 72 flush with bottomsurface 72 d (FIG. 12) of the front housing part. The flange has abottom hook portion 92 a and a top chamfered portion 92 b. The bottomhook portion overlaps an edge 94 of daughterboard 34. The top chamferedportion 92 b is engageable by the front bottom edge of adapter housing46 to prevent the bottom edge of the housing from “stubbing” the frontedge of the daughterboard during mating of the connector assemblies.

FIGS. 14-19 show in greater detail one of the fiber optic connectormodules 42 inserted into rear housing part 74 of daughterboard connectorassembly 28. Specifically, each module 42 includes a ferrule 96 forterminating multi-fiber cable 44, with a resilient boot 98 providingstrain-relief for the cable. The ferrule includes a pair of throughholes or passages 96 a (FIG. 15) for receiving a pair of alignment pins100 fixed to a pin keeper 102 which abuts against the rear of ferrule 96so that the distal ends of alignment pins 100 project forwardly of afront mating face 96 b of ferrule 96. A coil spring 104 is fixed to arear end of pin keeper 102 as described hereinafter, and a spring pushermember 106 is fixed to the rear end of the coil spring. Both pin keeper102 and pusher member 106 may be fabricated of molded plastic material.An integral, flexible latch arm 107 projects outwardly from the pushermember for latching the fiber optic connector module within rear housingpart 74 of daughterboard connector assembly 28. FIG. 16 shows that pinkeeper 102 has a receptacle 102 a at a rear end thereof for receiving afront end of coil spring 104, along with a locking flange 102 b forlocking with a coil at the front end of the spring. Although not visiblein FIG. 16, one of the locking flanges 102 b are disposed at eachopposite side of receptacle 102 a of pin keeper 102.

Similarly, FIG. 17 shows pusher member 106 to have a front receptacle106 a at a front end thereof for receiving a rear end of coil spring104. A locking flange 106b is disposed at each opposite side ofreceptacle 106 a for locking with a coil at the rear end of the coilspring.

FIGS. 18 and 19 show the procedure for assembling coil spring 104between pin keeper 102 and pusher member 106 and locking the coil springto those components. It should be noted that coil spring 104 is oval incross-configuration. A tool 110 has a generally oval shaft 112 forinsertion in the direction of arrow “G” into oval coil spring 104. Thetool then is rotated in the direction of anew “H” to effectively rotatethe coil spring and cause the front open end coil 104 a to lock behindflanges 102 b (FIG. 16) of pin keeper 102. This subassembly then ispositioned as shown in FIG. 19 so that the opposite open end coil 104 b(FIG. 18) is aligned with locking flanges 106 b of pusher member 106.Shaft 112 of tool 110 then is inserted in the direction of arrow “I”(FIG. 19) into a rectangular hole 114 in pin keeper 102 and into coilspring 104, and the tool rotated in the direction of arrow “J”. Thiseffectively locks the coil spring in position between the pin keeper andthe pusher member. Alignment pins 100 then are fixed within slots 116(FIG. 19) so that they extend from the pin keeper as seen in FIG. 15.Boot 98 then is inserted into opening 114 of the pin keeper; ferrule 96is positioned onto alignment pins 100; fiber optic cable 44 is insertedinto and through the entire assembly in the direction of anew “K” (FIG.15); and the alignment pins and cable are epoxied within the ferrule sothat an entire self-contained unit is formed as shown in FIG. 14.

Finally, FIGS. 20-22 show the mating procedure of backplane connectorassembly 26 and daughterboard connector assembly 28 in the direction ofarrows “A”, after the backplane assembly is mounted to backplane ormotherboard 32 and after the daughterboard connector assembly is mountedto daughterboard 34. These depictions also show that fiber optic cables40 are engaged with yet another substrate or board 120. Beforeproceeding, FIG. 20 best shows that adapter 36 of backplane connectorassembly 26 has a pair of actuator arms 122 spaced outwardly fromopposite sides thereof. The distal ends of actuator arms 122 are formedwith a latch hook 122 a and a forwardly facing chamfer 122 b.

Backplane connector assembly 26 and daughterboard connector assembly 28are mateable in a two-step process represented by FIGS. 21 and 22. Inthe first step, hooks 122 a of actuator arms 122 snap behind a pair ofpreliminary latch shoulders 124 (FIGS. 1 and 20) of rear housing part 74of daughterboard connector assembly 28. Latch hooks 74 b on the ends oflatch arms 74 a at opposite sides of the rear housing part already havelatched behind latch shoulders 72 a (FIG. 14) of front housing part 72.This prevents any rearward movement of any part of daughterboardconnector assembly 28 in response to the preliminary latching ofbackplane connector assembly 26 thereto. Further movement of theconnectors in the mating direction causes chamfers 122 b at the distalends of actuator arms 122 of adapter 36 to engage the chamfered distalends of latch arms 74 a of rear housing part 74 and move the latch armsout of engagement with latch shoulders 72 a. Latch hooks 74 b of latcharms 74 a now are free to move between latch shoulders 72 a and latchshoulders 72 b of the front housing part to provide a degree of floatingmovement between the two housing parts in the “Z” or mating direction.In other words, there is no floating movement between the housing partsin the “Z” direction until full mating occurs with the backplaneconnector assembly.

It will be understood that the invention may be embodied in otherspecific forms without departing from the spirit or centralcharacteristics thereof. The present examples and embodiments,therefore, are to be considered in all respects as illustrative and notrestrictive, and the invention is not to be limited to the details givenherein.

We claim:
 1. An alignment system between a pair of connectors mateablein a given mating direction, comprising: a first connector including ahousing having an alignment projection on one side thereof extendinggenerally transversely of said mating direction; and a second connectorincluding a housing having an alignment flange projecting forwardlythereof generally in said mating direction, said alignment flange beingflared outwardly generally transversely of said mating direction forengaging the housing of the first connector during mating and allowing adegree of misalignment between the connectors in an “X” directiongenerally perpendicular to the mating direction, and said alignmentflange including a slot for receiving the alignment projection of thefirst connector, the slot having a flared mouth allowing a degree ofmisalignment between the connectors in a “Y” direction generallyperpendicular to the mating direction and generally perpendicular tosaid “X” direction.
 2. The alignment system of claim 1 wherein saidalignment projection on the housing of the first connector comprises aprojecting rib which is elongated in said mating direction.
 3. Thealignment system of claim 1, including a pair of said alignment flangeson the housing of the second connector, the flanges being spacedtransversely of said mating direction and between which the secondconnector is mated with the first connector.
 4. The alignment system ofclaim 3 wherein said transversely spaced flanges comprise forwardlyprojecting arms having distal ends with inside surfaces which arediverging flared away from the housing of the second connector.
 5. Thealignment system of claim 4 wherein each of said arms includes one ofsaid slots in the inside thereof, each slot having said flared mouth,and the housing of the first connector having one of said alignmentprojections on opposite sides thereof for receipt in said slots.
 6. Thealignment system of claim 1 wherein said first connector comprises anopen-ended adapter, with one open end for mating with the secondconnector.
 7. The alignment system of claim 6 wherein said secondconnector comprises a fiber optic connector.
 8. An alignment systembetween an adapter and a fiber optic connector mateable in a givenmating direction, comprising: an adapter including a housing having anopen end and an alignment projection on one side thereof extendinggenerally transversely of said mating direction; and a fiber opticconnector including a housing having a pair of transversely spacedalignment arms projecting forwardly thereof generally in said matingdirection and between which the adapter is mated with the connector, thearms having distal ends which are diverging flared away from the housingfor allowing a degree of misalignment between the adapter and theconnector in an “X” direction generally perpendicular to the matingdirection, and said alignment arms including slots for receiving thealignment projections of the adapter, the slots having flared mouthsallowing a degree of misalignment between the adapter and the connectorin a “Y” direction generally perpendicular to the mating direction andgenerally perpendicular to said “X” direction.
 9. The alignment systemof claim 8 wherein said alignment projections on the housing of theadapter comprise projecting ribs which are elongated in the matingdirection.